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EMI Gaskets: Die-Cut, Water Jet & Flash Cutting

Posted on August 26, 2019 by brian in Articles, Blog with Comments Disabled

EMI gaskets are used in a variety of electronic devices where EMI/RFI is an issue including communications, military electronics, and RF applications.

When it comes to manufacturing EMI gaskets, there are three different methods MAJR Products uses:

1. Die-Cut
2. Water Jet
3. Flash Cutting

Each of these three manufacturing techniques have specific benefits associated with them and are best suited for a plethora of different products and materials including:

Conductive materials

Rubber

Cork

Foils

Silicones

Neoprenes

Porons

Thermal Materials

Tapes

Thin Films

Mylar

Kapton

1. Die-Cut

Die-cutting is a high-speed method of using a die to shear webs of low-strength materials in order to mass produce a wide range of industrial products, including gaskets. MAJR creates a predesigned steel rule die of the item, and then uses a press to replicate the item with the chosen material.

It can handle a variety of different materials for manufacturing gaskets, including:

Items Typically Created via the Die-Cut Method

Gaskets

Washers

Insulating foam

Vehicle parts

2. Water Jet

The water jet process of creating items, including gaskets, involves high pressure water that is forced through a small nozzle (0.010″ to 0.015″ in diameter) to produce a very precise cut of the material.

3. Flash Cutting

If the gaskets you need require thicknesses from .001” to .75” with tight tolerances MAJR utilizes the flash cutting method. The flash cutting method requires the use of a CNC machine that holds a blade in place to accurately and cleanly cut through the production material. Flash cutting results in a product with exact and precise measurements. Flash cutting also allows us to produce prototypes from CAD or PDF files.

Benefits of Flash Cutting

Allows for many customization options.

Can hold tolerances to .005”

Offers the fastest production turn-around time.

Exceptional for high volume applications.

The best method for projects where product aesthetics are important.

Does not cause concavity.

Produces clean edges.

Excellent for projects that require rapid prototyping.

Can utilize a variety of materials with the flash cut method.

Can be more cost-effective than jet cutting and die-cutting.

Items Typically Created via Flash Cutting

Gaskets

Soft plastics

Rubber

Laminated materials

Foam

Industrial fabrics

Technical textiles

Paper

MAJR Products Would Love To Take Care Of Your EMI Gasket Needs!

MAJR Products is an internationally recognized manufacturing leader of EMI/RFI shielding products, including gaskets. We have been serving the electronics industry by providing electromagnetic interference shielding products and solutions to some of the largest defense contractors in the country for close to 25 years.

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Majr Products, located in Saegertown, Pennsylvania, is the leading manufacturer of EMI/RFI gaskets, shielding and ventilation panel products. We've been designing and development solutions for over 25 years.